Cutting Insert Ridge Structure for Stable Milling Support
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Solution Overview
Problem
Existing cutting tools face challenges in maintaining stability and preventing deformation during milling and ramping cutting processes due to uneven force distribution, leading to issues like screw deformation and insert dropout.
Innovation Solution
The cutting tool assembly features an insert with diagonally intersecting upper and lower ridge portions, providing enhanced support surfaces that distribute forces more evenly across the tool holder, including angled cutting edges and support surfaces to manage principal, feed, and back component forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional cutting inserts are used without diagonal ridge portions, then the structure is simple, but force distribution is uneven causing screw deformation and insert dropout
Solution Approach 1:
The insert is divided into multiple functional regions by adding diagonal ridge portions that segment the support surface into distinct zones. These ridges create separate support areas that distribute forces more evenly across the insert, preventing concentrated stress points that lead to deformation and dropout.
Solution Approach 2:
Diagonal ridge portions are added to the insert structure, introducing a new dimensional element that intersects with the existing geometry. This additional dimensional feature creates multiple support planes and distributes loading in directions that were previously unaddressed, enhancing overall stability.
2Reliability
If conventional cutting inserts are used, then manufacturing is simple, but screw stress and displacement are high during intensive machining
Solution Approach 1:
The support surface is segmented into multiple zones by diagonal ridges, allowing each zone to independently manage specific force components. This segmentation enables more uniform stress distribution to the screw connection, reducing peak stresses and displacement during high-intensity machining operations.
Solution Approach 2:
Different regions of the insert are given different geometric qualities through the addition of diagonal ridge portions. Specific areas are designed with enhanced support characteristics to locally manage high-stress zones, while maintaining simpler geometry in lower-stress areas, optimizing both reliability and manufacturability.
3Strength
If conventional cutting inserts are used, then the structure is straightforward, but force distribution is uneven leading to tool breakage
Solution Approach 1:
Diagonal ridge portions are introduced as additional dimensional features that create multiple support planes intersecting at various angles. This multi-dimensional approach to force distribution captures load components in directions that a simple flat surface cannot, significantly improving force distribution and preventing tool breakage.
Solution Approach 2:
The support structure is segmented into multiple functional ridges that independently bear different components of the cutting forces. This segmentation distributes the total load across multiple discrete support elements, preventing any single point from experiencing excessive stress that would lead to failure.
Data Source
AI summary
An insert configured to be assembled to a tool for cutting a workpiece, includes: an upper surface including first to fourth upper corner portions formed in respective quadrants divided by a first imaginary vertical axis and a first imaginary horizontal axis that are perpendicular to each other; and a lower surface formed below the upper surface in a height direction and including first to fourth lower corner portions formed in respective quadrants divided by a second imaginary vertical axis and a second imaginary horizontal axis that are perpendicular to each other. A lower ridge portion protruding downward in the height direction is formed on the lower surface, and extends across the second and fourth lower corner portions, which are symmetrical with respect to a center of the lower surface.